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International Journal of Manufacturing and Production Engineering Original Research

Optimization of Process Parameters for AISI 304 Using Micro-EDM Drilling Process Through Response Surface Method

  1. Jinesh B. Shah Department of Mechanical Engineering, Atmiya University, Rajkot
  2. Kailashkumar P. Vala Department of Mechanical Engineering, Atmiya University, Rajkot

Abstract

The increasing demand for micro-parts in high-tech products, such as micro-electromechanical systems (MEMS) applications and micro-electronic devices, has driven significant advancements in micromachining technologies. Among the various micromachining processes, the fabrication of accurate microholes and pins is critical for the performance and reliability of miniature components. Micro-hole drilling plays a vital role by enabling the production of deep holes with excellent straightness, roundness, and surface quality. It is widely used in precision industries, including the manufacturing of watch components, camera parts, and automotive fuel injection nozzles. Electrical discharge machining (EDM), a non-contact machining process suitable for electrically conductive materials, is highly effective for producing high aspect ratio holes and is extensively utilized in the tool and die manufacturing sector. This study focuses on investigating the micro-EDM drilling process parameters for machining AISI 304 stainless steel using a 1 mm diameter brass electrode. The key input parameters analyzed are peak current (Ip), pulse-on-time (Ton), and pulse-off-time (Toff), while the primary output responses are tool wear rate (TWR) and material removal rate (MRR). A central composite design (CCD) combined with response surface methodology (RSM) has been employed to develop predictive models for performance characteristics. A three-level full factorial experimental design was implemented to systematically study the influence of drilling parameters. Multi-response optimization was carried out using the desirability function approach to identify the optimal combination of machining parameters that simultaneously minimize tool wear and maximize material removal rate. Finally, experimental validation of the optimized conditions will be conducted to confirm the effectiveness and reliability of the developed models. The findings of this study are expected to contribute to improved efficiency and precision in micro-EDM drilling processes for industrial applications.

Keywords

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